MASTERBATCHES. Masterbatch Application and Selection Guide for Irrigation Pipes

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1 MASTERBATCHES Masterbatch Application and Selection Guide for Irrigation Pipes

2 Table of contents Page Nr Introduction 2 Definitions 3 Key Performance Requirements of Irrigation Pipes 3 Drip Irrigation 3 Drip Irrigation Production 4 Laterals 4 Black Masterbatches 4 Weathering 5 Dispersion 5 Surface Smoothness 6 Thermal Resistance 6 Mechanical Properties 6 Summary of the Main Irrigation Pipe Standards 7 Introduction This brochure provides detailed information about Cabot s range of black masterbatches specifically designed for use in irrigation pipes. Performance information on each masterbatch is given relative to important application parameters such as weathering resistance, processability and mechanical properties. Information is provided on end-user requirements, industry test standards and other matters relevant to the production of irrigation pipes. The types of irrigation pipes covered by this brochure are: n Drip irrigation tubing n Drip irrigation pipe n Laterals 2

3 Masterbatches for Irrigation Pipes n Definitions Drip irrigation: the application of water through emitters as drops or small streams to or below the soil surface via relatively narrow tubing or pipe. Laterals: water delivery pipeline ( µm) that supplies irrigation water from the main line to sprinklers or emitters. n Key Performance Requirements of Irrigation Pipes Tubing Pipe wall thickness µm µm diameter mm mm pressure low depends on pipe thickness The key performance requirements are the following: n Weathering resistance according to recommended lifetime n Thermal resistance n Smooth surface finish n Excellent mechanical properties n Drip Irrigation Drip irrigation is used as a means of meeting crop demands giving increased yields and quality whilst efficiently managing water usage. Drip irrigation is of particular importance where water is scarce or expensive. It allows precise water application, minimal evaporation and reduced or eliminated run-off. It also ensures that conditions are less favourable for the onset of diseases due to the advantage of decreased water contact with crop leaves, stems and fruit. Drip irrigation can improve the efficiency of adding agricultural chemicals such as fertilisers. It reduces losses and allows better timing of their application to meet the crops needs. It is possible to completely automate drip irrigation with computerised humidity sensors detecting when irrigation is needed. Irrigation tubing and pipes usually have a small diameter (16 25 mm) and low wall thickness ( µm) giving the advantage of being flexible and coilable so that the pipe can be re-rolled for storage and subsequent re-installation. The irrigation system can be installed above or below ground. Under normal operating conditions, the internal water pressure is between 0.5 to 4 bars, depending on wall thickness. The drippers release water through their holes at a predetermined and maintained rate whilst the turbulent water flow of the drippers gives a self-cleaning effect with high resistance to clogging. Figure 1 illustrates a very simple drip irrigation system. Fig. 1: Drip Irrigation System Valve Backflow Preventer Pressure Regulator Filter Tubing Adapter Drip Tubing 45 cm Minimum Drippers End Cap 3

4 n Drip Irrigation Production The production of drip irrigation tubes/pipes is achieved through the extrusion of flexible pipe into which drippers are inserted at specific intervals; the pipe is drilled at each dripper. During production, the extruder is normally positioned at right angles to the line of the pipe and feeds a crosshead die. The dripper insertion unit is in line with the direction of extrusion, inserting drippers into the diehead. Line speed is sufficient to prevent the drippers from melting at the insertion point. Downstream are a vacuum sizing unit with a water pre-cooling chamber, cooling trough, and a de-watering device to dry the pipe before it enters the drilling unit. The holes are accurately positioned in relation to the drippers within the pipe. n Laterals Laterals are thicker, pressurised pipes that supply water from the mains, or other source, to sprinklers or emitters. Laterals are thus more rigid and need to be thicker to withstand the required pressures. They are normally fixed and remain in position for many years. Thus they have a higher weathering requirement than that of drip irrigation and are subject to regulations in most countries. Grade Formulation Irrigation pipe LL % standard carbon black with minimum process aid tubing 50% standard carbon black with process aid and antioxidant 50% standard carbon black with process aid and significant antioxidant package to compensate for use of recycled resins 40% weathering grade carbon black with process aid and antioxidant 40% weathering grade carbon black with process aid and significant antioxidant package for long term thermal stability or use of recycled resins 40% small particle size carbon black with process aid and antioxidant package tubing with improved gloss tubing containing recyclate tubing with improved weathering tubing for up to 20 years service life Thicker drip irrigation pipes and laterals n Black Masterbatches Cabot s range of black masterbatches has been developed to provide the technical performance demanded by the irrigation pipe manufacturer. This is achieved by selection of the appropriate carbon black, additive package and carrier system together with use of state-of-the-art mixing technology. The table on the left shows Cabot s recommended PLASBLAK masterbatches for irrigation pipes, that is both drip irrigation and laterals. Cabot s masterbatches have been specially designed to meet the requirements of different types of irrigation pipes. They have excellent dispersion and surface smoothness characteristics and will meet the necessary weathering, thermal resistance and mechanical properties demanded of them. 4

5 Figure 2 compares the performance of Cabot s irrigation pipe masterbatches. Performance improves from chart center. More detailed information on each property is given in the following sections: Fig. 2: Comparison of PLASBLAK irrigation pipe masterbatches Weathering n Weathering Dispersion Mechanical properties Irrigation pipes are required to have a durability to match their service life. Some of the current standards suggest that this is achieved by incorporating 2-2.5% carbon black usually of particle size below 25nm. These criteria can be met using. If the particle size is not specified then any of the other grades could be used. The weathering performance of some of Cabot s recommended black masterbatches for irrigation pipes is compared in Figures 3 and 4. All grades are compared at 120 µm whilst the higher performing grades are compared at 430 µm with data on LL4932 at 650 µm. This clearly demonstrates the superior performance when using a small particle size or weathering grade carbon black as in, and respectively. Nevertheless, the standard carbon black masterbatches, LL4932, and, are usually suitable for thinner drip irrigation tubing as this generally has less rigorous weathering requirements that the thicker pipes or laterals. n Dispersion Microscopic dispersion of carbon black in irrigation pipes is very important as the presence of undispersed carbon black agglomerates in the pipe wall can lead to premature failure of the pipe. The microscopic dispersion is usually assessed by a so-called press-out method involving the examination of thin hot-pressed compound samples under an optical microscope using transmitted light. Full details of the test can be found in the Cabot brochure Microscopic Dispersion Test for High Performance Pressure Pipes. The comparative performance of each of Cabot s irrigation pipe masterbatches is shown in the following table: Cabot masterbatch diluted in LDPE melt 0.3 at 2.5% carbon black using a single screw extruder LL Microscopic dispersion rating according to ISO The lower the rating, the better the dispersion. Retention in elongation at break (%) Thermal resistance LL4932 Surface smoothness Fig. 3: QUV-B weathering of irrigation pipe masterbatches at 2% carbon black loading in 120 µm LDPE film Retention in elongation at break QUV Exposure Time (hours) LL4932 Fig. 4: QUV-B weathering of irrigation pipe masterbatches at 2% carbon black loading in 430 µm LDPE film QUV Exposure Time (hours) LL4932 *Note: LL4932 results are on 650 µm sheet 5

6 n Surface smoothness The surface smoothness of the inner and outer walls of the pipe is important both for aesthetics and for fluid flow properties. This can be impacted by the carbon black dispersion quality, the carrier resin and, most importantly, the type and level of process aid in the masterbatch. The process aids used in pipe applications are normally fluoroelastomers. A fluoroelastomer will preferentially adhere to the metal of the pipe extruder thus coating the barrel, screw and die. The polymer melt will therefore have less drag at the metal surfaces and the flow will be more even. This eliminates problems such as sharkskin. It also reduces power consumption and melt temperature, helps to increase output and, most importantly improves gloss of the pipes. Based on the process aid content of the masterbatches, the surface smoothness will increase in the following order: LL4932 / // If additional process aid is required, then up to 1% of a process aid masterbatch such as LL8964 can be used. n Thermal Resistance Fig. 5: Elongation at break of PLASBLAK irrigation pipe masterbatches LL4932 Elongation at break (%) Fig. 6: Tensile strength at break of PLASBLAK irrigation pipe masterbatches 25 Oxidation induction time (OIT) tests were carried out on each of the masterbatches added to give 2% carbon black in LDPE resin (with no further additives). Measurements were made at 170 C and the results are given in minutes in the table below compared to natural LDPE resin, which had received the same thermal history: Formulation Measured OIT (in min.) Natural LDPE resin 12 4% LL4932 in LDPE resin 18 4% in LDPE resin 136 4% in LDPE resin > 360 5% in LDPE resin 220 5% in LDPE resin > 360 5% in LDPE resin 110 It can be seen that, which is designed to be used in conjunction with recyclate, and, designed for long term use, give the best thermal stability whereas the standard grade, LL4932, offers very little thermal stability compared to the natural resin. n Mechanical Properties Tensile strength at break (MPa) It is important for the carbon black used in irrigation pipes to be well dispersed, not only to give maximum UV protection but so as not to be detrimental to the mechanical performance of the pipes. Tensile strength and elongation at break measurements have been made on 120 µm film samples produced using the PLASBLAK irrigation pipe masterbatches diluted in LDPE to give 2% carbon black. Results are shown in figures 5 and 6. 0 LL4932 6

7 n Summary of the Main Irrigation Pipe Standards Country Reference Title Main masterbatch requirements Suitable Cabot grades International ISO 8779:2010 Plastic piping Polyethylene (PE) pipes for irrigation Specifications Carbon black 2.25 ± 0.25% International ISO 9261:2004 Agricultural irrigation equipment Emitting-pipe Specification and test methods Opaque and protected against UV degradation LL4932 France NF U October 1999 Irrigation techniques Reel machine Part 2: Specifications of polyethylene tubes for reel machines Carbon black 2.3 ± 0.3% France NF U October 1990 Irrigation equipment Polyethylene (PE) tubes for microirrigation equipment Specifications Carbon black density kg/m3 Carbon black volatiles 9.0% Carbon black average particle size µm Carbon black toluene extract < 0.01% by weight Carbon black 2.3 ± 0.3% Antioxidant to meet food contact requirements Antioxidant 0.3% OIT > 10 mins at 200 C Germany DIN-EN :1999 Irrigation techniques Reel machine Part 2: Specifications of polyethylene tubes for reel machines Carbon black 2.3 ± 0.3% Italy UNI-EN :2002 Irrigation techniques Reel machine Specifications of polyethylene tubes for reel machines Carbon black % Spain UNE 68076:1989 Irrigation equipment Emitting pipe Specifications and test methods Opaque and protected against UV degradation LL4932 Spain UNE 53367:2005 Plastics, PE32 and PE40 pipes for irrigation Characteristics and test methods Carbon black 2.25 ± 0.25% Carbon black µm Carbon black dispersion: requirements as shown in standard OIT 20 mins at 200 C Spain UNE :20000 Irrigation techniques Reel machine Part 2: Specifications of polyethylene tubes for reel machines Carbon black 2.3 ± 0.3% 7

8 Addresses EMEA Cabot Interleuvenlaan 15 i 3001 Leuven BELGIUM Tel.: Fax: ASIA-PACIFIC Cabot China Ltd. 558 Shuangbai Road Shanghai China Tel: Fax: SOUTH AMERICA Cabot Brasil Industria e Comericio Ltda. Rua do Paraiso andar Sao Paolo, SP Brazil Tel: Tel: (Customer service) Fax: ref: MB/Appl. & Sel. Guide for Irr. Pipes/06.12/ENG Notice and Disclaimer: The data and conclusions contained herein are based on work believed to be reliable; however, Cabot cannot and does not guarantee that similar results and/or conclusions will be obtained by others. This information is for informational purposes only. All product sales are subject to Cabot s terms of sale available at cabotcorp.com. Cabot Corporation, MA-U.S.A. All rights reserved PLASBLAK is a registered trademark of Cabot Corporation. 8

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